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Custom EVA Cases for Audio Brands

Custom EVA Headphone Cases for Audio Brands

Develop a case around your headphones, charging case and accessories. Choose the shell, interior layout, branding and packaging for your product. Share your dimensions and order requirements to discuss fit, sampling and production.

100 pcs per design (base MOQ; semi-custom, fully custom and special packaging projects may differ)
Project-specific testing and compliance support
TWS / IEM / Over-Ear
13+ Years Team Experience
Discuss Your Case Design
Custom EVA Headphone Cases for Audio Brands
Min. Order Qty100 pcs

✓No new tooling charge for eligible stock molds. Custom tooling is quoted separately.

100pcs per design (base MOQ; semi-custom, fully custom and special packaging projects may differ)
Project-specifictesting and compliance support
TWS / IEM / Over-EarTWS / IEM / Over-Ear
13+Years Team Experience

Why EVA Outperforms Hard Plastic for Custom Headphone & Earphone Cases

ProtectionNeoprene PouchPlastic ClamshellPengtour EVA Case
Device fit precisionGeneric paddingRigid but not device-specificCNC die-cut ±0.3mm to your device
Shock absorptionMinimalHard shell transfers impactEVA absorbs and distributes impact
TWS charging case slotNoneGeneric cavityZero-clearance microfiber-lined slot
Brand surface areaSmall patchSticker onlyDeboss/emboss full shell surface
Weight vs. protectionLight but poor protectionHeavy50–70% lighter than ABS equivalent

Pengtour Audio Storage Solutions — One Factory, Every Audio Form Factor

TWS Earbud Cases

TWS Earbud Cases

Zero-clearance charging case bay with microfiber-lined slot. Ear tip organizer tray (S/M/L sets). Cable coil slot. Documentation card sleeve. Optional: USB cable port through side wall.

  • Protection Challenge: TWS charging cases suffer surface scratches from repeated insertion and removal into generic cases. Loose earbuds rattle inside oversized cavities, stressing the hinge mechanism and scuffing the glossy finish.
  • Pengtour Engineering: Zero-clearance microfiber-lined charging case slot eliminates friction wear. Precision die-cut ear tip organizer tray holds S/M/L sets individually — no loose items, no rattle.

Compatible Products

AirPods / Sony WF / Samsung Galaxy Buds / custom TWS

Over-Ear Headphone Cases

Over-Ear Headphone Cases

Headband channel engineering (straight or curved arc, per actual fold radius). Earcup isolation: 20mm EVA pad per cup. Internal pocket: cable + 3.5mm adapter. Carrying handle or shoulder strap attachment.

  • Protection Challenge: Over-ear headphones face two failure modes in shipping: stacking pressure permanently bends the headband arc, and prolonged compression degrades ear cushion memory foam — reducing noise isolation and comfort that customers immediately notice on unboxing.
  • Pengtour Engineering: Headband channel engineered to exact fold radius (straight or curved arc per model). 20mm EVA isolation pad per earcup prevents cushion compression. Internal cable + adapter pocket keeps accessories separated from headphone surfaces.

Compatible Products

Sony WH-1000XM5 / Bose QC45 / custom over-ear

IEM Storage Cases

IEM Storage Cases

Custom-cast silicone or die-cut EVA ear shell tray. MMCX / 2-pin cable coil slot. Tool pouch insert for ear tip tools. Brushed aluminum nameplate option.

  • Protection Challenge: Metal-shell IEMs stored together risk metal-on-metal contact scratches between earpieces. Detachable MMCX and 2-pin cables tangle and pull on connector pins during removal, causing intermittent audio failure.
  • Pengtour Engineering: Custom-cast silicone or die-cut EVA ear shell tray with individual earpiece slots. Dedicated MMCX / 2-pin cable coil slot with ≥ 25mm bend radius prevents connector stress. Optional brushed aluminum nameplate for premium retail presentation.

Compatible Products

Custom IEM / CIEM / studio monitor earphones

Full Audio Kit Cases

Full Audio Kit Cases

Multi-tier EVA interior: headphone bay (top tier) + DAC/AMP bay with cable management (bottom tier). Divider system: fixed or configurable. Retail display window on lid optional.

  • Protection Challenge: Multi-SKU audio kits — headphone, DAC/AMP unit, cables, adapters — have mismatched weights and surface hardness. Hard DAC/AMP corners abrade adjacent headphone ear cushions, and cable connectors scratch DAC input ports during transport.
  • Pengtour Engineering: Multi-tier EVA interior: dedicated headphone bay (top tier) fully isolated from DAC/AMP bay with cable management (bottom tier). Fixed or configurable divider system prevents tier-to-tier contact. Optional retail display window on lid for shelf presentation.

Compatible Products

Headphone + DAC/AMP + cable multi-SKU kit

Need a Different Headphone Case Layout?

Share your headphone or earphone model, storage dimensions, accessory list and estimated order quantity. We will review the shell, interior layout and sampling requirements.

Four Dimensions of Customization — Custom Logo EVA Headphone Case, Your Way

Material & Exterior

  • EVA hardness 35–65 Shore C; finish: matte/gloss/fabric-wrap; color: custom Pantone; handle: rubber grip / metal bale / strap loop

Interior Layout

  • CNC die-cut per CAD; foam density 45–80 kg/m³; microfiber lining; elastic loops; zipper pocket; earphone-specific: headband channel, charging case slot, ear tip tray

Branding

  • Debossed/embossed shell logo; laser-engraved zipper pull; woven label; screen print; full-color insert card

Packaging

  • Retail carton / magnetic gift box / FBA-compliant master carton; barcode; hang tag

Full Configuration at Every Layer — EVA Headphone Case Material Options

Custom EVA Headphone Cases for Audio Brands
ComponentSpecificationNotes
EVA Shell35–65 Shore C; 15–22mm wall; density 38–55 kg/m³Consumer audio: softer; studio/field: harder
Interior Foam45–80 kg/m³ closed-cell; CNC die-cut ±0.3mm; microfiber liningReplacement insert available
Zipper#5–#8 coil or vislon zipper options; final component selected for the project configurationColor-matched available
HardwareZinc-alloy or ABS latches; nickel / matte black / gold finishHardware selection and any load-testing scope are confirmed for the final configuration
Handle/StrapTop rubber grip; wrist strap loop; optional carabiner clip—

From Your Audio Product to Our Case — Transparent OEM Headphone Case Development

STEP01

Design

Engineer maps headphone/earphone dimensions to cavity layout. Headband channel arc, charging case slot, ear tip tray, cable management modeled.

Timeline:
1–3 business days after complete specifications are received
Your Input Required:
Product CAD/dimensions + branding artwork
STEP02

Sampling

Physical prototype: EVA cold-pressed, interior die-cut, logo applied. Fit check with actual device.

Timeline:
About 7 calendar days after dimensions, artwork and payment are confirmed
Your Input Required:
Review & approve sample
STEP03

Sign-Off

Pre-production sample shipped. Final cavity, material, branding locked.

Timeline:
3–5 days (shipping)
Your Input Required:
Sign approval form
STEP04

Mass Production

IQC → IPQC → FQC (AQL 2.5) → Performance → OQC.

Timeline:
About 30–45 calendar days after sample approval and order confirmation
Your Input Required:
None
STEP05

Pack & Ship

Per spec. Pre-shipment inspection report. FOB/CIF/EXW.

Timeline:
Per schedule
Your Input Required:
Confirm packaging spec

Order quantity and tooling terms

  • Base MOQ: 100 pcs per design; this does not automatically cover semi-custom, fully custom or special packaging projects.
  • Semi-custom: From 400 pcs per design; final price confirmed in the quotation.
  • Fully custom: From 1,500 pcs per design; final price confirmed in the quotation.
  • Custom tooling charges are refundable for the same design when the first order reaches 2,000 pcs, according to the quotation terms.

Project-specific testing and compliance support

Testing requirements are agreed for each project and final configuration. Please tell us your target market and protection requirements so we can confirm the applicable test scope, supporting documents and any additional cost.

ProjectWhat HappensData
Project-specific testing and compliance supportTesting requirements are agreed for each project and final configuration. Please tell us your target market and protection requirements so we can confirm the applicable test scope, supporting documents and any additional cost.No new tooling charge applies to eligible stock molds. Custom tooling is quoted separately. Custom tooling charges are refundable for the same design when the first order reaches 2,000 pcs, according to the quotation terms. Material sample kits and any tooling promotion are confirmed with the quotation. FOB / CIF / EXW (Incoterms 2020) are available; the quotation will specify the applicable delivery location.

Frequently Asked Questions — Custom EVA Headphone & Earphone Cases

Common questions about ordering, pricing, production, and shipping

The base MOQ is 100 pcs per design. This does not automatically cover semi-custom, fully custom or special packaging projects. Semi-custom projects start from 400 pcs per design, and fully custom projects start from 1,500 pcs per design; final pricing is confirmed in the quotation.
Yes. Provide the charging case dimensions (L×W×H) and lid opening angle — we engineer a zero-clearance slot. Compatibility confirmed before mass production with a physical fit check.
Design feedback: 1–3 business days after complete specifications are received. Prototype sampling: about 7 calendar days after dimensions, artwork and payment are confirmed. Mass production: about 30–45 calendar days after sample approval and order confirmation. Sample fee: RMB 500–1,200, excluding shipping; any credit against the first production order is confirmed in the quotation.
Yes. For professional and studio monitor cases we offer a replaceable foam tile system — the customer reorders foam inserts without needing a full case replacement.
Testing requirements are agreed for each project and final configuration. Please tell us your target market and protection requirements so we can confirm the applicable test scope, supporting documents and any additional cost.
No new tooling charge applies to eligible stock molds. Custom tooling is quoted separately. Custom tooling charges are refundable for the same design when the first order reaches 2,000 pcs, according to the quotation terms. Material sample kits and any tooling promotion are confirmed with the quotation. FOB / CIF / EXW (Incoterms 2020) are available; the quotation will specify the applicable delivery location.

Still Have Questions?

Have a different headphone case question? Talk to our project team.

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Design-for-manufacturing feedback on your dimensions, layout and material choices.

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